Method of attaching a cladding to a vehicle

ABSTRACT

A mounting method for mounting a plastic panel ( 12 ) to a vehicle substrate provides a support flange ( 24 ) on an inner surface of the panel. A reference nodule ( 28 ) is positioned on the inner surface of the panel. An elongate bracket ( 14 ) has an upper edge ( 34 ) thereof engaging the support flange ( 24 ). The bracket ( 14 ) has a reference notch ( 40 ) engaging the reference nodule ( 28 ) positioning the bracket ( 14 ) relative to the panel ( 12 ). A plurality of retainers ( 18 ) are mounted on the bracket ( 14 ). A double-sided adhesive tape ( 16 ) has a first adhesive on a first side thereof compatible for adhesion to the bracket ( 14 ) and a second adhesive on a second side thereof compatible for adhesion to the panel ( 12 ). The first side of the adhesive tape ( 16 ) is applied to the bracket ( 14 ) and the second side is applied to the panel ( 12 ). The tape ( 16 ) allows expansion and contraction movement of the panel ( 12 ) while securely retaining the panel ( 12 ) to the vehicle substrate.

FIELD OF INVENTION

[0001] This invention relates to a method for attaching cladding andother body panels onto a vehicle.

BACKGROUND OF INVENTION

[0002] Plastic outer body panels have become more frequently used overmetal body panels. Plastic is advantageous over metal in order to reducevehicle weight and improve corrosion resistance Additionally, plasticpanels are less susceptible to damage from minor impacts.

[0003] Attachment of plastic panels to the metal substrate of thevehicle poses several problems. First, plastic and metal areincompatible for welding. Second, plastic panels must be mounted withoutdistortion as such distortion is visible. Third, plastic and metal havedifferent rates of thermal expansion. Fourth, certain plastic panelshave relatively high rates of hydroscopic growth in conditions of highhumidity.

[0004] In U.S. Pat. No. 4,529,244, a plastic body panel is provided withfasteners spaced about the panel. These fasteners allow for relativesliding movement between the panel and the metal substrate. To attachthe upper edge of the panel, a plastic reinforcement is attached to theback surface of the panel. The fasteners are retained by thereinforcement. To attach the lower edge of the panel, the fastenersextend through the panel into the substrate, requiring a special tool toclose each fastener.

[0005] In U.S. Pat. No. 4,973,102, a plastic body panel is provided withfasteners. A special bracket is mounted on the vehicle and the plasticpanel is fastened to the bracket. The plastic panel has longitudinalslots which allow relative movement between the plastic panel and thevehicle substrate.

[0006] The plastic panel attachment methods of the prior art have notbeen completely satisfactory. The plastic panels have been know toexhibit a “roping” effect, where the panels sag between the attachmentpoints. In other plastic panels, complicated moldings are required forthe fasteners which result in an increase incidence of sink marks on thefront face of the panel.

SUMMARY OF THE INVENTION

[0007] The disadvantages of the prior art may be overcome by providing asimple method of attaching a plastic panel to a vehicle substrate.

[0008] It is desirable to provide a method for attachment of a plasticpanel to a vehicle substrate, which method allows to relative expansionof the plastic panel relative to the vehicle substrate.

[0009] According to one aspect of the invention, there is provided amounting method for mounting a plastic panel to a vehicle substrate.There is provided a support flange on an inner surface of the panel. Areference nodule is positioned on the inner surface of the panel. Anelongate bracket has an upper edge thereof engaging the support flange.The bracket has a reference notch engaging the reference nodulepositioning the bracket relative to the panel. A plurality of retainersis mounted on the bracket. A double-sided adhesive tape has a firstadhesive on a first side thereof compatible for adhesion to the bracketand a second adhesive on a second side thereof compatible for adhesionto the panel. The first side of the adhesive tape is applied to thebracket and the second side is applied to the panel. The tape allowsexpansion and contraction movement of the panel while securely retainingthe panel to the vehicle substrate.

[0010] According to another aspect of the invention, there is provided aretainer. The retainer has an arrow shaped body having an axial extentand a pair of opposing tangs biased to permit only insertion of theretainer in a complementary aperture. A flange extends from the body andis positioned to limit insertion of the retainer in the complementaryaperture. A stud is axially spaced from the flange. The stud has anon-circular shape. A tab extends from the flange towards the stud andis rotationally spaced therefrom. A non-circular aperture is provided ona mounting surface. The aperture is sized to receive the stud, whereinthe retainer is mounted by inserting the stud through the non-circularaperture and the retainer is rotated until the tab snappingly engagesthe noncircular aperture locking the retainer to the mounting surface.

DESCRIPTION OF THE DRAWINGS

[0011] In drawing which illustrate embodiments of the present invention,

[0012]FIG. 1 is an exploded perspective view of a plastic panel withattachment of the present invention;

[0013]FIG. 2 is partial side sectional view of a panel and bracket ofthe present invention with the bracket being applied to the innersurface of the panel;

[0014]FIG. 3 is a partial section view of a panel and bracket of thepresent invention;

[0015]FIG. 4 is a perspective view of a retainer of the presentinvention;

[0016]FIGS. 5, 6 and 7 are plane views of the retainer and bracket ofthe present invention.

DESCRIPTION OF THE INVENTION

[0017] Referring to FIG. 1, a plastic panel 12 incorporating theattachment method of the present invention is illustrated. Generally,the attachment method comprises a bracket 14, a double sided strip ofadhesive tape 16, a plurality of retainers 18 and a secondary retainer20.

[0018] Plastic panel 12 has an outer contour of any desired shaping.Panel 12 can be made of any suitable plastic material, including TPO,PVC, polyurethane, polycarbonate, nylon, SMC (sheet molding compound).Panel 12 has an upper edge 22 having a molded downwardly extendingsupport flange 24 extending longitudinally of the panel 12. The depthand thickness of the flange 24 should be less than the maximum extentallowable to mold without forming sink marks in the outer contouredsurface of panel 12. Flange 24 extends substantially the length of panel12. At one end an opening 26 is preferably provided. A reference nodule28 is precisely positioned.

[0019] Optionally, panel 12 is provided with a dog house 30 having akeyhole for receiving retainer 20. The use of a dog house 30 andretainer 20 provides attachment for regions of the panel 12 havingreduced thickness which cannot accommodate the bracket 14.

[0020] The lower edge of panel 12 is provided with a series of moldedtangs 42 which are configured to clip and secure onto a flange on thesubstrate of the vehicle.

[0021] Bracket 14 is an elongate rigid substrate, preferably of metal orplastic. In the most preferred embodiment, the bracket 14 is a stainlesssteel. The bracket 14 has stepped contour in cross section asillustrated in FIGS. 2 and 3. The depth of the step depends upon thecontour of the panel 12. The bracket 14 has a series of spacedrectangular apertures 32 on a central portion thereof. The number ofapertures 32 depends on design criteria. The central portion has anupper edge 34 and a longitudinally extending rib 36. Rib 36 addsstructural rigidity to the bracket 14. The lower portion 3 g has anelongate surface on which double-sided tape 16 is applied.

[0022] Double-sided tape 16 has first surface with an adhesive which iscompatible with the bracket 14, which side is applied thereto. Theopposite side of tape 16 has an adhesive which is compatible with theplastic material comprising panel 12.

[0023] The upper edge 34 has at least one reference notch 40 spaced nearan end of the bracket 14. Reference notch 40 is used to align bracket 14on panel 12 which in turn aligns panel 12 on the vehicle. Preferably,bracket 14 has two notches on opposite ends so that the same bracket canbe used on opposite sides of the vehicle.

[0024] Bracket 14 can be made using any suitable method. Preferably, thebracket is roll formed and then apertures 32 and notches 40 are punchedor stamped. Alternatively, bracket 14 can be stamped in a singleoperation or successive operations.

[0025] Retainer 20 is a conventional “W” base—¼ turn attachment clip,commonly used and commercially available from ITW Plastics.

[0026] Referring to FIG. 4, retainer 18 is illustrated in greaterdetail. Retainer 18 has a flat arrow head shaped body 44 having tangs 46extending from opposite faces of body 44. A flange 48 extendsorthogonally from body 44. A rectangularly shaped stud 50 is mounted ona neck 52 to space the stud 50 from the flange 48. Preferably, neck 52has a thickness slightly greater than the thickness of the bracket 14.Stud 52 is sized to be received within aperture 32 of bracket 14. A pairof tabs 54 extends from the flange 48 on opposite sides of stud 52.Preferably, the tabs 54 are diametrically spaced 90° relative to thestud 52. Any amount of rotation could be used provided the retainer 18becomes attached to the bracket 14. The width of the tabs 54 correspondsto the width of apertures 32 and the diametric spacing corresponds tothe length of aperture 18. The depth of tabs 54 corresponds with thethickness of bracket 14. Retainer 18 is preferably injection molded froma plastic material, preferably nylon or acetal.

[0027] Optionally, retainer 18 can have a sealing flange extending fromthe body 44 and positioned between the flange 48 and the ends of tangs46.

[0028]FIGS. 5, 6 and 7 illustrate the method of installing retainer 18.To install the retainers 18, the stud 50 is aligned with and theninserted through the aperture 32. Flange 48 will flex to accommodatetabs 54. The retainer is then rotated a ¼ turn until the tabs 54 snapinto engagement with the aperture 32. Once the tabs 54 have snapped intoplace, the retainers 18 are substantially secured to the bracket 14. Adesired number of retainers 18 are attached to the bracket 14 is asimilar fashion. As it is now apparent to those skilled in the art,retainers 18 could be installed before or after the bracket 14 has beenapplied to the panel 12.

[0029] In the preferred embodiment, the bracket 14 will have thedouble-sided adhesive tape 16 applied to portion 38. The exposed side ofthe tape 16 will have a removable film covering the adhesive. When thebracket 14 is ready to be applied to the panel 12, the operator removesthe film and then inserts the edge 34 under flange 24, aligns thereference notch 40 with the reference nodule 28, rotates the bracketuntil the tape 16 adheres to the panel 12.

[0030] The substrate of the vehicle has a series of aperturescorresponding with the positions of the retainer 18. The bottom edge ofthe panel 12 is applied to a lower flange thereby catching tabs 42thereon. The retainers 18 are then inserted through the apertures on thevehicle substrate until the tangs 46 snap into place.

[0031] The flange 24 will rest upon the bracket 14 along the lengththereof. Thus, the upper edge 22 of the panel 12 will be fully supportedand will not suffer from the “roping” effect. Further, the panel 12 isadhesively connected with the bracket 14. Expansion and contraction ofthe panel 12 will be accommodated by the tape 16 and is not dependentupon the retainer 18 moving relative to the vehicle substrate. The panel12 is thus able to move relative to the vehicle substrate anywhere alongits length except for the reference nodule.

[0032] The invention has been described in an illustrative manner, andit is to be understood that the terminology which has been used isintended to be in the nature of words of description rather than oflimitation. Many modifications and variations of the present inventionare possible in light of the above teachings. It is, therefore, to beunderstood that within the scope of the appended claims the inventionmay be practiced otherwise than as specifically described.

What is claimed:
 1. A mounting assembly for mounting a plastic panel toa vehicle substrate, said mounting means comprising: a support flange onan inner surface of said panel, an elongate bracket having an upper edgethereof engaging said support flange for supporting said panel, aplurality of retainers mounted on said bracket and positioned along saidbracket to engage cooperating apertures in said vehicle substrate forattaching the panel thereto, and said bracket having a lower edge beingadhesively connected to said panel enabling expansion and contractionmovement of said panel relative to said bracket.
 2. A mounting assemblyas claimed in claim 1 further comprising a reference nodule on one ofsaid panel and support bracket, and a reference notch on the other ofsaid panel and support bracket, said reference nodule engaging saidreference notch positioning the bracket relative to said panel.
 3. Amounting assembly as claimed in claim 2 further comprising adouble-sided adhesive tape having a first adhesive on a first sidethereof compatible for adhesion to said bracket and a second adhesive ona second side thereof compatible for adhesion to said panel, saiddouble-sided tape adhesively connecting said bracket to said panel.
 4. Amounting assembly as claimed in claim 3 wherein said first side isadhered to said bracket and said second side is adhered to said panel.5. A mounting assembly as claimed in claim 4 wherein said flangedownwardly extends from an upper edge of said panel.
 6. A mountingassembly as claimed in claim 5 wherein said assembly further comprisesat least one dog house on said inner surface and at least one otherretainer mounted on said dog house, said retainer positioned to engage afurther cooperating aperture in said vehicle substrate.
 7. A mountingassembly as claimed in claim 6 wherein said reference nodule is on saidpanel and said reference notch is on said support bracket. 8 A mountingassembly as claimed in claim 7 wherein said plurality of retainers andfurther retainer each comprise: an arrow shaped body having an axialextent and a pair of opposing tangs biased to permit insertion of theretainer in a complementary aperture, a flange extending from said bodyand positioned to limit insertion of said retainer in said complementaryaperture, a stud axially spaced from said flange having a non-circularshape, at least one tab on said flange extending towards said stud androtationally spaced therefrom, said bracket having a non-circularaperture sized to receive said stud, wherein said retainer is mounted tosaid bracket by inserting said stud through said non-circular apertureand rotating said retainer until said tab snappingly engages saidnon-circular aperture locking said retainer to said bracket.
 9. Incombination, a vehicle panel comprising a support flange extendinglongitudinally along an inner edge surface thereof, an elongate supportbracket having an upper edge thereof engaging said support flange in asupporting relation with said panel, a plurality of retainers mounted onsaid bracket and positioned therealong to engage cooperating aperturesin a vehicle substrate for attaching the panel to a vehicle, anddouble-sided adhesive tape having a first adhesive on a first sidethereof adhesively connecting a lower edge of said bracket thereto and asecond adhesive on a second side thereof adhesively connecting saidpanel thereto, said double-sided adhesive tape enabling expansion andcontraction movement of said panel relative to said bracket.
 10. Acombination as claimed in claim 9 wherein one of said panel and supportbracket has a reference nodule, and the other of said panel and supportbracket has a reference notch engaging said reference nodule positioningthe bracket relative to said panel.
 11. A combination as claimed inclaim 10 wherein said panel further comprises at least one dog house onsaid inner surface and at least one other retainer mounted on said doghouse, said retainer positioned to engage a further cooperating aperturein said vehicle substrate.
 12. A combination as claimed in claim 11wherein said reference nodule is on said panel and said reference notchis on said support bracket 13 A combination as claimed in claim 12wherein said plurality of retainers and further retainer each comprise:an arrow shaped body having an axial extent and a pair of opposing tangsbiased to permit insertion of the retainer in a complementary aperture,a flange extending from said body and positioned to limit insertion ofsaid retainer in said complementary aperture, a stud axially spaced fromsaid flange having a non-circular shape, at least one tab on said flangeextending towards said stud and rotationally spaced therefrom, saidbracket having a non-circular aperture sized to receive said stud,wherein said retainer is mounted to said bracket by inserting said studthrough said non-circular aperture and rotating said retainer until saidtab snappingly engages said non-circular aperture locking said retainerto said bracket.